Let the Dust Settle

by Bruno Ferrarese and Bruno Gazzignato – Idrobase Group |Published March 2025

Dust suppression in industrial plants is crucial for ensuring a safe working environment and maintaining operational efficiency. Without appropriate dust control measures, these particles can accumulate in plants and spread to the surrounding environment, compromising air quality and endangering the health of workers. In addition, dust accumulation can lead to equipment malfunction and reduce the overall plant productivity. Therefore, the adoption of effective dust suppression technologies is essential to minimize these risks and to ensure optimal operation.

Thanks to the installation of a misting system, we were able to improve the air quality and consequently the working environment at the Young Poong foundry in Seokpo-myeon, South Korea, one of the world’s leading manufacturers of nonferrous metals. This intervention has enabled the control and suppression of dust, ensuring a safer and healthier environment for workers. It exemplifies how our technology can bring tangible benefits to complex and highly specialized industrial sectors.
Idrobase Group provides solutions for PM2.5 (particulate matter) and dust suppression, including the following:

• Technologically advanced, scalable, and programmable industrial misting systems, powered by nebulization modules and designed to supply misting lines of any length and configuration
• Fog-maker cannons capable, like our other industrial misting systems, of producing ultra-fine mist (11–24 microns). These vary in size, range (from a few meters up to 90 meters), and options for mobility or positioning (mobile versions, wall-mounted, etc.).

 

For the specific needs of the foundry, the nozzle line solution was chosen.

Here are the key features of this industrial misting system.

1. Excellent ability to capture ultrafine particles—thanks to the ultrafine size of the misted water particles (10–24 microns), the system effectively captures airborne dust, reaching even blind spots and ensuring uniform coverage in the most challenging areas.

 

2. High-pressure method allows for efficiency and savings—the system uses high-pressure technology, allowing for powerful and instantaneous water misting, thus reducing water consumption compared to “low-pressure fog” solutions. This method ensures a denser and more effective mist for dust suppression, using less water and making the system more cost-effective and efficient.

 

3. Versatility of application—the misting system is suitable for different industries thanks to a modular configuration that allows it to adapt to the specific needs of each plant, ensuring effective dust suppression even in complex environments.

 

4. Advanced control via IoT (internet of things): the system is equipped with an IoT control system, which allows it to automatically manage the on/off functions, adjusting for time and the amount of nebulization through a centralized control panel. This automated control optimizes operational efficiency and ensures timely intervention in areas where dust is most concentrated.

 

 

 

 

 

 

 

 

So, at the Young Poong foundry a misting system with fixed lines was built, specially designed for dust suppression in the most critical indoor areas.

The water mist captures dust particles, promoting their precipitation on the ground and preventing their dispersion into the environment. The sections of interest include the material storage areas, the grinding and furnace facilities, and the loading and unloading areas.

The installed system was adapted to the specific needs of the different areas.

• Material Storage—Four lines of 180 meters with double nozzles inclined at 120° spaced one meter apart ensure uniform coverage. This configuration is essential for suppressing dust during the handling, storage, and transportation of nonferrous materials.

 

• Furnace— Two lines with double nozzles inclined at 120° spaced 60 centimeters apart create an effective barrier for dust suppression. The nozzle inclination allows optimal coverage of the furnace area, reducing the risk of material dispersion, controlling fumes, and lowering temperatures during furnace processing.

 

• Loading and unloading areas—A perimeter line of 120 meters with double nozzles inclined at 120° surrounds the material handling areas. The total of 400 nozzles directed inward allows for dust suppression during loading and unloading operations.

 

The results achieved are the misting system has not only significantly reduced the amount of dust in the environment but has also contributed to improving the overall atmospheric environment.

The generated mist also has a positive effect in neutralizing odor; offers a lowering of temperature, counteracting heat waves during summer periods; and enables humidity control, contributing to healthier and safer working conditions.

Through the adoption of this misting system, a significant reduction in particulate matter in industrial production areas has been achieved, improving not only the health and safety of workers but also the operational efficiency and environmental impact of the plant.

The implementation of technologies such as these is an important step toward improving working conditions and environmental sustainability in industrial settings.

IDROBASE GROUP
      Since 1986 Idrobase Group provides different tools for PM2.5 abatement and dust suppression according to specific needs: a range of fog makers, modules, and misting lines to capture dust pollution and make them fall to the ground and hot- and cold-water pressure washers to clean polluted surfaces.